New VMC for Efficiency with Large, Complex Workpieces

For most of a week thick crowds swarmed over Mazak’s IMTS 2012 exhibits, taking in the details and insights about over 20 machine tools demonstrated there. One machine gaining attention and prompting some buzz audible above the whirring spindles was the Vortex 1060V/8 Single, a vertical machining center developed to process large, complex components — up to 59.06 in. (1,500 mm) diameter, 57.09 in. (1,450 mm) high, in weights up to 6,614 lb.— with single set-ups. High productivity may be first among its attributes, but its single table design also makes it a cost-effective, efficient design that demands only a minimum of floor space.

Mazak’s targets for the Vortex are machining operations that specialize in parts for aerospace and construction machinery. The VMC performs simultaneous 5-axis surface contouring with a 50-taper, 50-hp (37 kW) tilting spindle, capable of maximum speeds of 10,000 rpm for exceptionally high metal removal rates. An optional 5,000-rpm spindle that generates up to 368.8 ft-lbs. of torque for heavy-duty cutting is also available.

Speed and productivity are also promoted by the new VMC’s rapid traverse times —1,654 ipm (60 m/min) — as well as its large 80-tool magazine.

The Vortex 1060V/8 Single incorporates Mazak’s MX Hybrid Roller Guide System in the X-, Y- and Z-axes. The reliability of this system reportedly will increase the machines’ durability and reliability, and promote long-term machine accuracy. It’s also credited for increasing vibration dampening, extending tool life, handling higher load capacities, and eliminating tramp oil in the coolant because it uses a more environmentally sound, grease-based lubrication system.

Mazak’s new Matrix 2 CNC control drives the Vortex 1060V/8 Single. It’s a platform that was designed specifically to optimize 5-axis machining. “Within the control are both enhanced hardware and software functionalities that make the control easy to use while also delivering high accuracy and increased productivity,” according to a statement.

“Control hardware performance is much faster with higher processing speeds for small increment operation,” Mazak continued. “Furthermore, a 5-axis spline interpolation function included in the control’s software provides smooth toolpaths from long block-by-block programs, easy tool vector control and shorter cycle times as well as superior 5-axis surface finishes.”